化工與化學(xué)制藥行業(yè)EHS與PSM管理

OverviewHSE/PSMforChemicalIndustryMr.GaoBoContact:139-17-242-130Sep.2012I

ObjectiveItisanawarenesstrainingprogram.Thecourseaimstohelpnon-EHSprofessionalstounderstandthebasicEHSconceptinchemicalindustryandestablishbasicknowledgeofEHSmanagement.Thecoursewilllast2hours.Afterthecourse,thelearnerwill?

understandtheimportanceofEHSinchemicalindustry?

gettoknowtheoverviewofEHSmanagementin

chemicalindustryOverviewEHSManagementforChemical

Industry2II

ContentOverviewEHSManagementforChemical

Industry3III

Definition?

AIChE:

AmericanInstituteofChemicalEngineers?

CCPS:

CenterforChemicalProcessSafety?

CSB:

U.S.ChemicalSafetyandHazardInvestigation

Board?

CSR:

CorporateSocialResponsibility?

EHS:

Environment,IndustrialHygieneandSafetyManagement?

FTA:

FaultTreeAnalysis?

GMP:

GoodManufacturingPractice?

Hazop:

HazardandOperabilityAnalysis?

IH:IndustrialHygieneU.S.NationalInstituteofOccupationalSafety&?

NIOSH:Health?

OSHA:

U.S.OccupationalSafetyandHealthAdministration?

PS:

ProductStewardship?

PSM:

ProcessSafetyManagementOverviewEHSManagementforChemical

Industry41Importanceof

EHSOverviewEHSManagementforChemical

Industry51.TheImportanceof

EHSBhopal,India1984DuringthenightofDecember2-3,1984,astoragetankcontainingmethylisocyanate(MIC)attheUnionCarbidepesticideplantleakedgasintothedenselypopulatedcityofBhopal,India.Itwasoneoftheworstindustrialaccidentsinhistory.Estimatesofthedeathtollvarygreatly.Mostsourcessayatleast3,000peoplediedfromimmediateexposuretothegas,whilehigherestimatesgoupto8,000.Inthetwodecadesfollowingthenightofthedisaster,approximately20,000additionalpeoplehavediedfromthedamagetheyreceivedfromthegas.OverviewEHSManagementforChemical

Industry61.TheImportanceof

EHSHebeiKeeperChemicalPlant,Feb.29th201216killed,and43injuredandhospitalizedOverviewEHSManagementforChemical

Industry71.TheImportanceof

EHSHeinrichPyramidOverviewEHSManagementforChemical

Industry81.TheImportanceof

EHSTheRealCostsofaccidentsNotonlytheinsurablecosts?

Reputation?

Productioncontinuity?

Crisis?

Debt?

BankruptIcebergofAccidentOverviewEHSManagementforChemical

Industry92OverviewEHSManagementOverviewEHSManagementforChemical

Industry102.OverviewofEHSManagementTheLogicofEHSManagementActionCheckDoPlanOverviewEHSManagementforChemical

Industry112.OverviewofEHSManagementRiskBasedEHSManagementOverviewEHSManagementforChemical

Industry122.OverviewofEHSManagementEHSManagementCycleOverviewEHSManagementforChemical

Industry132.OverviewofEHSManagementTheBroaderSenseofEHS1.ProcessSafety2.OccupationalSafety&Health3.EnvironmentManagement4.ProductStewardship5.Warehouse&TransportSafety6.CommunityAwareness7.Security8.CorporateSocialResponsibilityOverviewEHSManagementforChemical

Industry142.OverviewofEHSManagementKeyProcedureofEHSManagementOverviewEHSManagementforChemical

Industry152.OverviewofEHSManagementKeyProcedureofEHSManagementOverviewEHSManagementforChemical

Industry162.OverviewofEHSManagementLevel1Level2Level3Localproceduresandpractices(design,maintenance

&operation)AccidentsPreventionControlsMitigationControlsMAPotentialHowEHSManagementWorksOverviewEHSManagementforChemical

Industry17全面損失控制管理EHSR法律法規(guī)符合性危害識別與風(fēng)險評估監(jiān)管產(chǎn)品工藝安全企業(yè)社會責(zé)任員工職業(yè)健康與安全CSR環(huán)境管理C環(huán)境企業(yè)社會責(zé)任CSR管理安防產(chǎn)品監(jiān)管A工藝安全產(chǎn)品儲運安全社區(qū)意識3ProcessSafetyManagementOverviewEHSManagementforChemical

Industry193.ProcessSafetyManagementWhatIsChemicalProcessinPSM?OverviewEHSManagementforChemical

Industry203.ProcessSafetyManagementExampleofaSimplifiedProcessFlowDiagramOverviewEHSManagementforChemical

Industry213.ProcessSafetyManagementWhatIsProcessSafetyManagement?ProcessSafetyManagementistheapplicationofmanagementprinciplesandsystemsto

theidentification,understanding,andcontrolofprocesshazardstoprotectemployees,facilityassetsandtheenvironment.OverviewEHSManagementforChemical

Industry223.ProcessSafetyManagementWhyProcessSafetyManagementIsVital??

ProcessSafetyManagementcontainsrequirementsforpreventingorminimizingtheconsequencesofcatastrophicreleasesofchemicalsthatare:?Toxic?

Reactive?

Flammable?

Explosive?

Thesereleasesmayresultintoxic,fireorexplosionhazards?

Anumberofcatastrophicaccidentshaveoccurredresultinginlossoflifeandgreatpropertydamage.OverviewEHSManagementforChemical

Industry233.ProcessSafetyManagementProcessAccidentLeadstoDisasterBhopal,India(1984)?

2,000deathsIsocyanatereleasePasadena,TX(1989)?

23deaths,132injuriesPetroleumexplosionCincinnati,OH(1990)?

2deathsExplosionSterlington,LA(1991)?

8deaths,128injuriesChemicalreleaseOverviewEHSManagementforChemical

Industry243.ProcessSafetyManagementCausesoftheProcessAccidentFlixborough1974?

Managementofmodificationfailure?

Inadequateexperience?

OverstretchedresourcesPiperAlpha1988?

Failuresinshifthandover?

Permittowork?

Training?

Communications?

AuditingOverviewEHSManagementforChemical

Industry253.ProcessSafetyManagement光氣及光氣化工藝Phosgenationprocess重氮化工藝Diazotizationprocess123456789電解工藝（氯堿）chlor-alkaliproduction氧化工藝Oxidationprocess101112131415氯化工藝Chlorinationprocess過氧化工藝Peroxidationprocess硝化工藝Nitrificationprocess胺基化工藝Aminationprocess合成氨工藝Ammoniacalsynthesisprocess磺化工藝Sulfonationprocess裂解（裂化）工藝Crackingprocess聚合工藝PolymerizationProcess氟化工藝Fluorinationprocess烷基化工藝AlkylationProcess加氫工藝HydrogenationprocessChinaRegulated

HighRiskProcessOverviewEHSManagementforChemical

Industry263.ProcessSafetyManagement14ElementsofPSM01.ProcessSafetyInformation02.ProcessHazardAnalysis03.OperatingProcedures04.EmployeeParticipation05.Training06.Contractors07.Pre-StartupSafetyReview08.

MechanicalIntegrity09.HotWorkPermit10.

ManagementofChange11.

Incident

Investigation12.EmergencyPlanningandResponse13.ComplianceAudits14.TradeSecretsAdobe

AcrobatDocumentOSHA3132OverviewEHSManagementforChemical

Industry273.ProcessSafetyManagementPSMStructureOverviewEHSManagementforChemical

Industry283.ProcessSafetyManagement3.1ProcessSafetyInformation?

MaterialSafetyDataSheets(MSDS)?

Pipingandinstrumentationdiagrams(P&IDs)?

Blockflowdiagrams?

Materialandenergybalancecalculations?

Relevantconsensusstandards?

Materialsofconstruction?

AvailabletoallaffectedP&IDSampleemployees?

AvailableforProcessHazardAnalysisandrevalidationsOverviewEHSManagementforChemical

Industry293.ProcessSafetyManagement3.2ProcessHazardAnalysis?

ArguablytheMostDifficultPartofPerformingtheStandard?

PHAprocessisdynamicandsubjecttorevisionwheneverchangesaremade?

PerformedbyYourPSMTeam?

TakesSignificantTime&Effort?

PHA’sareNeverEnding?

What-if?

Hazop?

FTA?

PHASoftwarePHAWorks5.0OverviewEHSManagementforChemical

Industry303.ProcessSafetyManagement3.3OperatingProcedures?

StandardOperatingProcedures?

DointandemwithJobHazardAnalysis(JHAs)?

Meshwithtrainingprogram?

PartnerwithQualityTeam(ISO9001)tocreatetrainingmatrixandmanageddocumentsOverviewEHSManagementforChemical

Industry313.ProcessSafetyManagement3.4EmployeeParticipation?

Employeesarerequiredtobeanactivepartoftheprocessandyourwrittenprogramsneedtodocumentwhatrolesemployeesplay,theirinvolvementinthedevelopmentoftheprograms,andcontinuingparticipationintheprocess.?

Participationwithtrainingandsupervisiontodeterminethefrequencyandcontentofinitialandrefreshertraining.?

Participationtodevelopandreviewoperatingandmaintenanceprocedures.?

Participationinincidentinvestigationsregardingthecoveredprocess.OverviewEHSManagementforChemical

Industry323.ProcessSafetyManagement3.5Training?

Theemployershallpreparearecord:a.

Identityofemployeeb.

Dateoftrainingc.

Meanstoverifythatemployeeunderstoodtraining?

Ataminimum,refreshertrainingshallbeprovidedatleasteverythreeyearsandmoreoftenifnecessarytoeachemployeeinvolvedinoperatingaprocess.OverviewEHSManagementforChemical

Industry333.ProcessSafetyManagement3.6Contractors?

EmployerDocumentation:?

Contractemployeeinjuryandillnesslogsrelatedtoworkincoveredprocessareas.?

ContractEmployerDocumentation:?

Recordsshowingemployeesreceivedtraininginandunderstandssafeworkpracticesrelatedtotheprocessonornearwheretheywillbeworkingsotheyperformtheirjobssafely.OverviewEHSManagementforChemical

Industry343.ProcessSafetyManagement3.7Pre-StartupSafetyReview?

Check,doublecheck,andreviewanychanges,modifications,additionsmadeinaPSMcoveredarea–beforeyoufliptheswitch.OverviewEHSManagementforChemical

Industry353.ProcessSafetyManagement3.8MechanicalIntegrityTheemployershalldevelopandmaintainamasterlistofallequipmentspecificallycoveredbythestandard,andequipmentthatisimportanttosafetyof

theprocessandconductpreventivemaintenance.?Pressurevesselsandstoragetanks?Pipingsystemsincludingvalvesandotherpipingcomponents?Reliefandventsystemsanddevices?Emergencyshutdownsystems?Controls(includingmonitoringdevicesandsensors,alarms,andinterlocks)?Pumps?Rotatingequipment?Heatexchangeequipment?Electricalgenerationanddistributionequipment?Un-interruptablepowersupplies?Emergencypower

supplyequipment?FireprotectionequipmentOverviewEHSManagementforChemical

Industry363.ProcessSafetyManagement3.9HotWorkPermit?

Welding,cutting,braising–makesureonlytrainedpersonnelperformthesefunctions?

Havetrainedfirewatchers(alignwithfireextinguisher/fireresponsetraining)OverviewEHSManagementforChemical

Industry373.ProcessSafetyManagement3.10ManagementofChangeRelatedto:?

PSI?

MechanicalIntegrity?

P&IDs?

HotWork?

ContractorSafety?

EmployeeTraining?

PSSRCreateformalizedsystemtoreviewallchangestoprocessareasincluding:?

Rawmaterialchanges/substitutions?

Personnelchanges?

OperatingProcedures?

Processparameters?

Facilitychanges(HVAC/roof/fireprotection/??..)OverviewEHSManagementforChemical

Industry383.ProcessSafetyManagement3.11IncidentInvestigationInvestigateIncidents&Beginwithin48-hoursNear-MissesIncidentInvestigationTeamwithProcessKnowledgeReatainReports5-yearsFollow-upSystemforRecommendationsReportwithConclusions&RecommendatonsOverviewEHSManagementforChemical

Industry393.ProcessSafetyManagement3.12EmergencyPlanningandResponseCallinallresourcesandmakeplancomprehensive:?

InformationTechnology(IT)DisasterRecoveryPlan?

BusinessContinuity?

Security?

Communications/PublicRelations?

EmployeeAssistanceOverviewEHSManagementforChemical

Industry403.ProcessSafetyManagement3.13ComplianceAudits?

ToensurethatPSMiseffective,employersmustcertifyevery3yearsthattheyhaveevaluatedcompliancewiththestandard?

Mustbecompletedbyatleastonpersonknowledgeableintheprocess?

Reportmustbedevelopedanddocumented?

Deficiencycorrectionsmustbedocumented?

LasttwocomplianceauditsmustbekeptonfileOverviewEHSManagementforChemical

Industry413.ProcessSafetyManagement3.14TradeSecrets?

EmployersmustmakeallnecessaryinformationrequiredtocomplywithPSM,regardlessoftradesecrets,availabletopersonsinvolvedindevelopingorcreating:a.

Compilingprocesssafetyinformationb.

PHAsc.

SOPsd.

Incidentinvestigationse.

Emergencyplanningandresponsef.

Complianceaudits?

ConfidentialityagreementsareallowedOverviewEHSManagementforChemical

Industry424OccupationalSafetyandHealthOverviewEHSManagementforChemical

Industry434.OccupationalSafetyandHealth01.OccupationalSafety&HealthElementsofOccupationalSafety&HealthLegislationManagement02.HazardIdentificationandAssessment03.JobSafetyAnalysis04.HazardCommunication05.IndustrialHygiene&Ergonomics06.ChemicalManagement07.PersonalProtectiveEquipment(PPE)08.Lockout/Tagout09.PermittoWork(PTW)10.FirstAidOverviewEHSManagementforChemical

Industry444.OccupationalSafetyandHealth4.1OccupationalSafety&HealthLegislationManagementOverviewEHSManagementforChemical

Industry454.OccupationalSafetyandHealth4.2HazardIdentificationandAssessmentThebasicapproachofhazardidentification:?Jobhazardanalysis?FEMA?BrainStormOverviewEHSManagementforChemical

Industry464.OccupationalSafetyandHealth4.3JobSafetyAnalysisOverviewEHSManagementforChemical

Industry474.OccupationalSafetyandHealth4.4HazardCommunication?

Hazardwarningtag?

PPEalertingtag?

MSDS?

Labelonchemicalcontainer?

Periodicaltraining/meetingonsafetyOverviewEHSManagementforChemical

Industry484.OccupationalSafetyandHealth4.5

IndustrialHygiene&ErgonomicsAcute

Result

——

OccupationalSafetyChronicResult——

OccupationalHealth?

Legalrequirements?

RegulatedIHhazard?

IHhazardidentification?

ExposuremonitoringandcomparewithOEL/STEL?

ExposureControl?

Periodicalcontroleffectassessment?

Periodicalpersonneloccupationalhealthexam?

PeriodicaltrainingOverviewEHSManagementforChemical

Industry494.OccupationalSafetyandHealth4.6ChemicalManagement?

Chemicalprocurement?

ChemicallistandMSDS?

Labelonchemicalcontainer?

Chemicaltransportation?

Chemicalloading/unloading?

Chemicalstorage:warehouse/tankfarm?

Thesafetyduringuseofchemicals?

Wastechemicalmanagement?

FirstAidofchemicalburning?

Emergencyresponseonspill,leakage,fire,explosionOverviewEHSManagementforChemical

Industry504.OccupationalSafetyandHealth4.7PersonalProtectiveEquipment(PPE)?

Relatedtoriskassessment?

PPEdemandidentification?

RiskbasedPPEselection?

PPEMatrix?

PPEprocurement?

PPEdistributedtoemployees?

TrainingonuseofPPE?

ThemaintenanceofPPE?

ThePPEeffectivenesstesting?

RefresherofPPEOverviewEHSManagementforChemical

Industry514.OccupationalSafetyandHealth4.8Lockout/Tagout6stepsforthecontrolofdangerousenergyduringmaintenance/repairing/testing?

Preparationforshutdown?

Shutdowntheequipment?

Isolatetheequipment?

Applylockout/tagoutdevices?

Controlstoredenergy?

VerifyisolationofequipmentOverviewEHSManagementforChemical

Industry524.OccupationalSafetyandHealth4.9PermittoWork(PTW)Forhighrisktasks,PTWsystemisimplemented.?

Hotwork?

Workatheight?

Enteringconfinedspace?

Excavation?

Temporaryelectricity?

OtherdefinedhighrisktasksOverviewEHSManagementforChemical

Industry534.OccupationalSafetyandHealth4.10FirstAid?

FirstAidkit?

Firstaidfacilities?

On-sitedoctor/nurse?

Firstaidtraining?

FirstaiddrillFirstaidcannotreplacehospitalmedicaltreatmentOverviewEHSManagementforChemical

Industry545EnvironmentManagementOverviewEHSManagementforChemical

Industry555.EnvironmentManagement01.WasteWaterManagement02.SolidWasteManagement03.Off-gasManagement04.NoiseonBoundaryofSiteManagement05.